Insulated water-tight container

ABSTRACT

An insulated container for shipping, transporting, or storing warm or cold items is disclosed, useful for maintaining temperature of items stored or shipped within the container, the container assembly consisting of at least one layer of rigid or semi-rigid material, and at least one layer of flexible, thermally insulating, water-resistant material, in the form of a pouch, which pouch is secured to the rigid material at areas which allow easy reconfiguration of the container to form a finished container having desirable insulating and water-resistant characteristics.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 10/191,671, and application Ser. No. 11/514,509, from which applicant claims priority.

TECHNICAL FIELD OF THE INVENTION

The present invention relates to an insulated container for shipping, transporting, or storing warm or cold items. More particularly, the present invention relates to a new thermally insulated container assembly, which assembly is water-tight and thermally protective of its contents, as well as insulated, so that container contents may be maintained at constant temperature, while fluids or solids associated with the contents, if any, may be retained within the container during storage or shipment. The container assembly utilizes a layer of rigid or semi-rigid material, and at least one layer of flexible, thermally insulating, reflective, water-tight material, in the form of a pouch or pocket, fastened to the rigid material in such fashion as to allow easy and inexpensive manufacture, and compact storage in a “knock down,” substantially flat, configuration. When desired, a user may quickly and conveniently manipulate the knock down assembly to create a volume within the container, thereby forming a finished container having desirable insulating and water-resistant characteristics in which the user may keep or store warm or cold items with their associated fluids.

BACKGROUND ART OF THE INVENTION

In many insulated containers, rigid materials are combined with insulating materials to form containers having insulating properties. By use of such containers, product suppliers may ship perishable products refrigerated or at room temperature, live or frozen, to customers while controlling the environment in which the perishable products are placed, or while simply extending the useful life of such products before they spoil. Examples of such uses for containers used in shipping include the shipment of fresh fish, in which a customer has requested that the product not be frozen, fresh flowers, around which a cool and moist environment should be maintained, and frozen tissues for research. With all such products, maintenance of constant or low temperature will help preserve freshness and quality of the products. Maintenance of constant or low temperature will also extend the useful life of the products, and often thereby increase the distance over which such products may be shipped, as extending the time during which a product is preserved extends the time for shipment during which such product may reach its destination. In other insulated containers of this same general description, the usefulness of the container is in preserving the temperature of foods or beverages used in picnics, family outings, ball games, and other recreational activities.

Containers of these types which have been successfully employed for these purposes include insulated containers made from cardboard and individual pieces of insulating material, such as Styrofoam or other lightweight foam type insulation. These types of containers are often constructed by gluing individual pieces of insulating foam material to the interior surfaces of a cardboard container, which is formed as a box, or by inserting separate foam pieces to insulate each container surface. While these containers offer advantageous high thermal resistance, cutting and gluing pieces of foam to construct the finished container requires substantial assembly time, with the result that containers formed in this way are expensive to assemble, and are not water tight.

Similar containers include insulated containers made of plastic foam, typically expanded polystyrene, formed in a mold to the desired shape. In some cases, additional corrugated pieces may be used to provide additional structural support. While this type of container also offers high thermal resistance and, in addition, ease of assembly, the resulting container is rigidly set in its final form at the time of manufacture. As a result, this type of container requires substantial floor space and volume to store and transport prior to, during, and after use. Moreover, expanded polystyrene is generally considered to have a high impact on the environment as undesirable byproducts are released upon its manufacture and disposal. In addition, polystyrene decomposes slowly, and, due to its airy and bulky nature, it occupies a large volume in land-fill disposal sites.

Another type of container generally suited for shipment of perishable products consists of generally rigid walls made of corrugated cardboard or other suitable material, to which is bonded a flexible, sealable, insulative material having bubbles of gas entrapped therein to provide thermal insulation. One form of such material is commonly referred to as “bubble wrap,” however rubber or plastic foam or other material having the characteristics described herein may be employed in the present invention. The flexible material may have a reflective surface, or an additional layer of flexible reflective material, attached to the rigid walls or flexible, sealable, insulative material, to increase thermally resistant efficiency. While this type of container is well suited to some applications, and has distinct advantages over other types of insulated containers, the containers of this type appearing in prior art, with the exception of one disclosed in a prior patent to this inventor, do not allow for easy assembly by a user, with resulting savings in time and costs. Nor, generally, are such containers in the prior art water-tight for retention of fluids, such as runoff from melting ice, associated with the products shipped.

Finally, various apparatus and methods have been used in container construction to preserve the contents within the container from breakage or degradation due to mechanical shock experienced while moving the container. Such apparatus and methods include utilization of elastomeric sheets secured to the interior of a hard-case carton, combinations of foam bodies and air sacs placed within the container, and various inflatable mats, tubes, envelopes, and flaps. However, such apparatus and methods do not exhibit a knock-down, hard-shell, exterior, and a pre-located and secured, interior pouch, thereby simultaneously also exhibiting water-tight, thermally-insulative, and shock-absorbing properties.

It may be appreciated, in light of the foregoing discussion, that there is a need for an environmentally friendly, affordable, insulated container, suitable for shipping perishable products, and suitable for providing convenient temperature control, where the container is easy to manufacture, thermally resistant, watertight, resistant to mechanical shock, lightweight, compact prior to assembly, and easy to assemble by a user. The present invention is directed precisely to such useful characteristics.

A number of schemes have been devised to accomplish one or more of the goals set forth above. These schemes include single-piece and multi-part containers of cardboard, foam, and plastic flexible, sealable, insulative material materials. Various designs and configurations for such apparatus include:

U.S. Pat. No. 3,772,712 to Renn et al., which discloses a bag, the lower portion of which is secured within the lower portion of a container.

U.S. Pat. No. 3,952,940 to Malcolm, which discloses a container for liquids formed of a paperboard carton and an inner tubular liner of flexible plastic film adhered to portions of the walls of the carton.

U.S. Pat. No. 3,957,195 to Lin, which discloses a container assembly composed of a plastic bag and a hollow paper body.

U.S. Pat. No. 4,030,603 to Angell, which discloses a method for packaging fragile articles in which such articles are held by heat treat-shrink wrap within a frame and hard container.

U.S. Pat. No. 4,194,439 to Zimmermann, which discloses a method for making a folded lined paperboard container and liquid proof liner having an automatic bottom which locks in a set-up position when the container is manipulated from a flat knock-down condition to a set-up position.

U.S. Pat. No. 4,235,065 to Freeman, which discloses a method for packaging fragile articles in which an expandable tube is layered between such articles, and then filled with gas and closed with a valve, thereby occupying space within a container.

U.S. Pat. No. 4,262,801 to Avery, which discloses an apparatus having flexible and outer container bodies having inflatable chambers which hold articles placed there between.

U.S. Pat. No. 4,284,205 to Hirata, which discloses a pouch inserted in a cylindrical shell to create a foldable cup.

U.S. Pat. No. 4,573,202 to Lee, which discloses an apparatus having an outer shell and an inner inflatable envelope.

U.S. Pat. No. 4,660,737 to Green et al., which discloses a packaging container formed of a flexible pouch inserted in a closely form-fitting relationship with an outer rigid carton.

U.S. Pat. No. 4,854,474 to Murray et al., which discloses a collapsible, self-standing, liquid-tight drinking cup formed of a plastic film liner secured to the inner surfaces of foldably interconnected paper-board panels.

U.S. Pat. No. 4,889,252 to Rockom et al., which discloses an insulated container formed of corrugated paperboard and a layer of flexible material having air bubbles and foil.

U.S. Pat. No. 5,009,326 to Reaves et al., which discloses an insulated multi-part container of corrugated cardboard, folded and stapled to form an enclosure, with one-piece insulated liner.

U.S. Pat. No. 5,638,978 to Cadiente, which discloses an insulated waterproof container for the shipment of produce.

U.S. Pat. No. 6,296,134 to Cardinale, which discloses an insulated water-tight container consisting of at least one layer of rigid or semi-rigid material, and at least one layer of flexible, thermally insulating, water-resistant material, in the form of a pouch secured to the rigid material.

In the above-noted inventions, and in other prior art, cardboard, when formed into a box, is a popular material in the shipping industry because it is inexpensive and relatively light weight when compared to its strength. As a result, insulated containers composed in part of cardboard or paperboard help minimize shipping costs. However, cardboard alone is not suitable in those applications in which temperature should be maintained within the container, and it is not suitable in those applications where the contents of the container is a fluid, such as water, or where fluid is important to preserving the contents. Prior efforts at achieving a suitable container for such purposes have therefore focused on configurations and materials which have desirable characteristics when used in combination with cardboard, or which have both rigidity and such characteristics when used without cardboard.

As a result, various inventions of the prior art, such as those of the above-noted patents, employ combinations of various insulating materials, whether rigid or flexible, and water-tight or water-resistant layers or barriers. A variety of insulating and water-resistant effects may be achieved where these materials are combined and formed as directed by prior art. Thus, good insulative properties are achieved by containers utilizing preformed foam, however preformed foam does not allow compact storage, while foam sheets require expensive assembly and cannot achieve water-tightness. In the alternative, cardboard with flexible plastic bubble sheets may be easy to manufacture, however most such arrangements are not water-tight, or are time consuming for a user to assemble if stored and shipped in compact, “knock down” form. In addition, the construction of such arrangements are somewhat expensive because multiple sheets are required.

The present invention is directed to combining these desirable features to achieve an insulated container suitable for shipment or storage of a wide variety of products in the same container, notably perishable products. Accordingly, a single, low-cost container, may be utilized for wide variety of purposes, and at the same time have those characteristics which make the container widely available, quickly assembled, and easily employed. While the devices disclosed in prior patents fulfill their respective objectives, prior patents and inventions do not describe or suggest an insulated, water-tight shipping container, easy and inexpensive to manufacture, compact in storage and shipment, and quickly reformed by a user to produce the final container having the desirable characteristics mentioned herein.

DISCLOSURE OF INVENTION Summary of the Invention

An insulated container utilizing corrugated cardboard or paperboard to achieve structural rigidity consists in its simplest form of the cardboard, an insulating material, and perhaps a means for resisting the transmission of fluids or vapors through the cardboard. The insulating material is typically fastened to the cardboard, or simply placed within the cardboard carton after the cardboard is formed into an open box. The means for containing fluids or vapors, if present, may be placed inside the insulating material, or between the insulating material and the cardboard. Padding or Styrofoam “peanuts” are often also used to cushion the contents of the container against mechanical shock, and such protective systems may be employed with insulating and water-resistant materials in appropriate applications.

The present invention provides a new assembly, easy and inexpensive to manufacture, and compact in its folded “knock down” configuration, in which configuration the assembly may be stored or shipped while occupying a minimum of space. The present invention is an assembly easy for a user to quickly reconfigure into a insulated and water-tight container, which container is suitable for storing or shipping products requiring a controlled temperature, and which container may also hold fluids and vapor found with the other contents of the container.

In one preferred embodiment of the present invention, an insulated container assembly is comprised of a rigid or semi-rigid outer container or box, and a one-piece insulated liner in the form of a bag or pouch. The outer container may be composed of corrugated cardboard, paperboard, plastic, or other material having sufficient structural rigidity and strength to satisfy the application at hand. Accordingly, corrugated cardboard is the likely material of choice for an insulated container designed to ship cut flowers, and for many other applications, while colored plastic might be more suitable to, and therefore chosen for, a picnic basket or sporting event beverage cooler application.

The outer container generally will include four sidewalls, a top and a bottom, or flaps which form a top and a bottom when folded over the opening at the end of the container formed by the four sidewalls. The top or flaps are generally appended to the rigid or semi-rigid sidewalls of the container or, preferably, formed integrally with such side walls in a single die-cut “blank.” If the container is formed in such a single blank, the blank is then folded along preset fold lines to form the sidewalls, and at least two opposing edges of the blank are secured to one another with adhesive to form a tubular section of sidewalls, with closure flaps extending from each end of the tubular section. The top and bottom flaps may consist of a single flap at each side of the blank, or more than one flap at each side of the blank, so that one or more flaps are available for closure at the end of the tubular section when the sidewalls and tubular section are formed from the blank upon its folding. In the alternative, the blank may be cut without end flaps at one end, and separate top lid closure separately cut and supplied to the user along with the side wall tubular section. The bottom flap or flaps (depending on the number of flaps utilized to close the bottom end of the tubular section) are affixed so as to form part of the bottom closure. Thus, for instance, where a single flap is used to bridge the bottom opening of the tubular section, an area along its edge is attached to the opposing side of the tubular section. Where two flaps are used to bridge the bottom opening, the flaps are attached to each other. In each case, at least two additional flaps affixed to adjacent sides of the tubular section are desirable to complete the closure at the bottom of the tubular section.

The general nature of the invention being thus explained, it may be appreciated that confusion may arise in terminology as the details of the blank are described, along with the method of construction resulting in a finished container ready for use. To avoid such confusion, the following terminology will be used:

The four portions of the die-cut blank which may be bounded on their sides by fold or score lines (or an edge of the blank) when the blank is in lay flat form, which portions bear flaps and may be folded to create a tubular form, will be referred to as “side panels.” The same four portions of the blank when folded, whether before or after expansion of the container, will be referred to as “sidewalls.” The exception to this terminology is with reference to two of the opposing side panels among these four side panels, which opposing side panels are intended to bend to allow the container to expand and collapse when in use, and so have, as set forth more fully below, additional fold or score lines. These opposing side panels may also be referred to as “folding side panels” and the corresponding sidewalls in the expanded container may also be referred to as “folding sidewalls.” The remaining two side panels, also opposing one another, but intended to move toward and away from one another during the process of expanding or collapsing the container, may also be referred to as “non-folding side panels,” and the corresponding sidewalls in the expanded container may also be referred to as “non-folding sidewalls.”

The edges of the side panels having appended top flaps, which edges form a single line when the blank is in lay flat form, will be referred to as the “top” edges of the side panels, and the single line of such side panel top edges the “top” of the blank. Such top edges will also define the “top” of the container when the blank is folded and the container expanded and ready for use; the top flaps comprise additional material appended to the top edges of the side panels. The edges of the side panels having appended bottom flaps, which edges form a single line when the blank is in lay flat form, will be referred to as the “bottom” edges of the side panels, and the single line of such side panel bottom edges the “bottom” of the blank. Such bottom edges will also define the “bottom” of the container when the blank is folded and the container expanded and ready for use; the bottom flaps comprise additional material appended to bottom edges of the side panels.

When the blank is in lay flat form, each side panel will have a “width” measured parallel to the top of the blank, such widths being equal to the distance between the fold or score lines between panels (or between a fold or score line and an end of the blank). The width of each top or bottom flap appended to each side panel will be measured consistently, i.e., parallel to the top of the blank. When the blank is in lay flat form, each side panel will have a “height” measured perpendicular to the top of the blank, such heights being equal to the distance between the fold or score lines drawn between each side panel and its appended top and bottom flaps. The distance each flap extends from the side panel or sidewall to which it is appended will be the “length” of such flaps, and the distal edge of each flap shall be its “end.”

As a result of the above terminology, when the side panels are folded and the container constructed according to the present invention, the widths of two side panels of the blank will equal the length of the sidewalls of the finished container, while the widths of the remaining (alternate) two side panels of the blank will equal the width of the sidewalls of the finished container. It may be appreciated, however, that if all such sidewall widths are not equal, the width of two opposing sidewalls may correspond to the overall length of the expanded container. As a further result of this terminology, when the side panels are folded and the container constructed according to the present invention, the height of all side panels of the blank will equal the height of the sidewalls of the finished container.

Continuing, the blank which will form the outer container of the present invention, prior to folding, may be cut so that all side panels are of equal width, thereby creating a square when the expanded container is viewed from above (i.e., a square “footprint” for the expanded container). However, a more usual configuration for the sidewalls of the expanded container results when the blank is cut so as to form two wider side panels and two narrower side panels (all side panels remaining equal in height), thereby creating a rectangle when the expanded container is viewed from above (i.e., a rectangular “footprint” for the expanded container). As noted above, two of the side panels, those corresponding to the folding sidewalls, will generally have scores, or fold lines, extending the height of such side panels. The folding side panels will comprise at least alternate panels in the die-cut blank. Accordingly, such folding side panels will also be opposing sidewalls of the container in its expanded configuration. The scores or fold lines of the folding sidewalls generally extend from approximately the midpoint of the top of each folding side panel, to approximately the midpoint of the bottom of the corresponding folding side panel. While these folding side panels may be folded by a user without fold or score lines, the score or fold lines of the folding side panels allows the folding side panels to be easily folded top to bottom, approximately in half, during manufacture, and the corresponding folding sidewalls to be easily folded in the same way again after manufacture to expand or collapse the container during use. Such folding results in movement of the non-folding sidewalls toward each other, thereby collapsing the container to its knock-down configuration. In containers having wider and narrower sidewalls, in a preferred embodiment, the scores and fold lines of the folding side panels are preferably formed in the narrower side panels. However, the present invention also works well when the wider side panels bear scores or fold lines, and the present invention specifically includes such a configuration.

The bottom of the outer container of the present invention (in its expanded configuration) will, as noted above, usually comprise bottom flaps. The bottom flaps appended to the side panels are generally cut to correspond approximately in width to the width of such side panels. However, at least one such flap is also generally cut sufficiently long to meet or overlap the end of the corresponding flap appended to the opposing sidewall. That is, when the tubular section of side panels is manipulated into its open, volume creating configuration, the flaps appended to two of the opposing sidewalls meet or overlap one another at their distal ends when such flaps are folded toward one another. An area of overlap for two such bottom flaps is important to the operation of some embodiments of the present invention, as such overlap provides an area to apply adhesive or other fastening means so that the bottom flaps may be affixed to one another (along their area of overlap). This area of overlap is generally provided by forming the bottom flaps of approximately equal length, with the exception of one such bottom flap which is formed longer, its distal edge thereby extending further from the sidewall to which it is appended. However, other means for providing an area of overlap for two bottom flaps are easily envisioned, and within the scope of the present invention, as are other attachment means for bottom flaps when such flaps do not overlap.

When the bottom flaps are affixed to one another, one of the flaps may then be folded against or along the edge of the other flap, thereby allowing the opposing, non-folding sidewalls to which the flaps are affixed to approach each other. In this way the outer container may be collapsed to a knock-down configuration or, by reversing the movement of the opposing sidewalls, expanded to its open configuration, ready to receive articles within the volume created thereby. While the same flexibility between configurations may be achieved with a single flap appended to a bottom edge of one sidewall and extending to the bottom edge of the opposing sidewall (and affixed to an area adjacent to such edge, the flap being folded approximately in half during collapse), the preferred embodiments utilize two flaps as set forth herein.

The remaining flaps of the closure at the bottom of the container, that is, the bottom flaps appended to the remaining folding sidewalls, may be cut long or short. However, whether long or short, such flaps also bear scores or fold lines extending substantially their length, from approximately the midpoint of their line of intersection with a sidewalls to approximately the midpoint of their distal edge. Such fold or score lines extend the fold or score lines impressed into the opposing folding sidewalls, thereby allowing these bottom flaps to bend, easily following the movement of the corresponding folding sidewalls as these sidewalls are bent or straightened during manufacture or use.

It may be appreciated that, once the ends of the blank are affixed to one another to form the tubular section, the above system of (i) folding along the length of the two opposing folding sidewalls and (ii) folding at least one bottom flap appended to the non-folding sidewalls, allows the container of the present invention to be collapsed around its “perimeter” (i.e. from folding sidewall to folded bottom flap to opposing sidewall) to its knock-down configuration. By simply reversing such folding, thereby straightening both the folding sidewalls and the bottom flaps, a user may expand the container to its full volume.

The top of the container may then be closed by the top flaps, or by separate closure usual in the industry, and sealed. In one such closure and sealing arrangement, the top may consist of four top flaps, two of which bear cutouts for insertion of the ends or corners of the other two top flaps, which top flaps may be scored for easy bending or folding. The top of the outer container, or the top flaps, may, in addition, feature a handle, or be capable of being formed into a handle, for ease of carrying the finished insulated container, or the outer container may carry, separately from the top or flaps, a handle attached to its exterior. It may also be noted that the folding sidewalls may be folded “outwardly,” so that the fold extends from the body of the (knocked down) container, or the narrow sidewalls may be folded “inwardly,” so that the fold extends within the body of the container in its knock down configuration.

The one-piece insulated liner of the present invention may be formed from one or more sheets of flexible, thermally insulative, waterproof and air tight material (the “pouch material”), or the liner may be formed from separate sheets having only one of these properties each. In its simplest form, the material utilized to form the liner need only be air tight, so that the liner, once formed from such material into a pouch as set forth below, may be water-tight when sealed at its top. Generally, however, both thermal insulation and waterproofing may be most simply accomplished in a single sheet utilizing recently available and inexpensive materials. One material of choice using currently available materials is a flexible plastic layer having at least one layer of air bubbles entrapped therein (sometimes commonly known as “bubble wrap”) laminated to a layer of metalized polyester or foil.

This pouch material may be formed in a variety of ways, but is commonly formed by bonding a first layer of smooth plastic to a second layer of plastic having a surface with regularly spaced depressions pushed into it. Upon bonding, the first and second layer adhere in areas in which depressions are not formed, while remaining separated layers at the areas of the depressions. The result of such bonding is entrapment of air in the areas of the second layer in which the depressions were formed. Alternate means for constructing pouch material incorporate baffles between successive layers, which baffles comprise plastic “walls” between layers. The result of such construction is a material having at least two layers, where the layers do not themselves contact one another, but only contact the walls extending between the layers. The insulative characteristics of such a layered construction are enhanced.

A pouch material having further enhanced thermal resistance characteristics may be obtained by constructing these materials in the presence of an inert gas, or other gas having a lower heat transmission rate than air. In such case, the bonded layers of the pouch material thereafter holds the gas selected within the walls of the liner. Regardless of the gas or gas mixture utilized, a third layer of plastic is often bonded to the second layer of plastic in a fashion similar to that set forth above, thereby further entrapping gas or gases between the second and third plastic sheets. Further plastic sheets, creating more gas bubbles, may be added in this way to increase thermal resistivity. The multiple sheets after such fabrication together create a single, multi-layer sheet of pouch material. One or more of the individual sheets of plastic comprising the pouch material may be composed of a plastic having reflective properties, to thereby reduce heat transfer by radiation. In the alternative, another layer of reflective plastic or other material may be attached to the pouch material, or separately used with the pouch material to reduce heat loss by radiation.

Other configurations are possible based on similar water-tight and thermally insulative materials, such as those developed by Berkeley Labs. Using such alternative materials, a gas may be injected into the walls of the pouch through an open valve, and held within the liner by the airtight material and the valve upon its closing. Alternatively, a portion of the pouch material may be composed of permeable elastomeric material, and the space within the walls of the liner injected with a small amount of gas other than air, oxygen or nitrogen. Such other gas may be selected from among a wide variety of gasses which have lower diffusion rate across the permeable material than air, gasses such as carbon dioxide. Finally, its is also possible to construct the present invention utilizing multilayer plastic material wherein the layers, while holding a gas as in the preferred embodiment, are connected only at their edges. In such way, an inflatable pouch may be created which expands to surround and protects fragile materials after the pouch has been inflated.

In one preferred embodiment of the present invention, a single sheet of pouch material is simply cut into a rectangular shape, folded over once, and the cut edges matched. Some edges of the pouch material are then sealed, leaving unsealed those edges most distant from the fold line, thereby forming a pouch, with top opening away from the fold line, and base of the pocket at the fold line. Alternatively, a single sheet may be folded over after being cut, and sealed along a side adjacent to, and along a side opposite to, the fold line.

A variety of means may be utilized to seal the pouch material, however the sealing of edges to create a pouch may be quite easily accomplished in one preferred embodiment by the application of heat to the areas to be sealed as such areas are pressed together. The combination of heat and pressure causes the flexible plastic material to melt slightly, deflating bubbles incorporated into the material, and bonding together successive layers of plastic. Alternate means for sealing the edges to form a pouch include gluing, folding and sewing, or other means calculated to form a water-tight seal. The cutting and sealing as described results in water-tight and insulative pocket, which may remain flat as originally folded and sealed or expanded to allow the insertion of cargo.

The plastic pouch material is cut to a width which, when so folded and sealed, will fit conveniently within the sidewalls of the outer container when the outer container is flattened into its knock down configuration. As so sized, the pouch material will also fit conveniently within the sidewalls of the outer container when it is expanded to its final three dimensional shape, and may follow the side walls in such expansion if attached to them. The pouch material is also cut to a length which, when so folded, sealed, and placed within the outer container, will extend through the outer container when it is flattened, and out the top and bottom of the flattened container (excluding flaps). When so placed within the outer container, the base of the pocket of insulating material, at the fold line, extends below the bottom edges of the sidewalls of the outer container, while the opening of the pocket, away from the fold line, may extend past the top edges of the sidewalls of the outer container to allow ample material to overlap or join the top edges of the pouch material to seal the pouch after expanding and filling the container.

One variation on the construction of the pouch within the scope of the present invention includes the forming of cuts in the pouch material extending from the top edge of the pouch a distance approximately equal to the length the pouch extends above the top of the sidewalls when the pouch is properly placed on the blank. Such cuts may be utilized to allow fastening of the material on either side of the cuts to the top end flaps, and so easy closure of the pouch when the top flaps are folded to closure. Another variation on the construction of the pouch within the scope of the present invention includes using pouch material which is inflatable after manufacture of the pouch. Such pouch material may be formed into a pouch and placed uninflated on the blank, and fastened to it, prior to constructing the tubular arrangement of the present invention. Once the tubular arrangement is formed and the bottom flaps fastened to each other or to the opposing wall as set forth below, the completed container may be shipped in its lay flat configuration, and the user may inflate the insulative pouch after the container is expanded to its usable configuration. The inflatable pouch meeting these characteristics must be specially designed with areas at each corner where the pouch cannot be inflated, such areas then remaining uninflated during later expansion. Such corner areas are necessary to effective operation of a pouch which may be later inflated by a user, as only by not inflating corners can a pouch of this type fit and expand correctly into a hard container. It may be noted that pouch material having this description is available, as is at least one finished pouch having the desired characteristics.

In one preferred embodiment of the present invention, the distance the base of the pocket of insulating material extends from the sidewalls of the container is approximately equal to or greater than one half the width of the narrowest sidewall. As a result, the pocket may be drawn open to form a square or rectangle when viewed from either top or bottom, and the dimension of the resultant square or rectangle allows the pocket of insulating materials to approximately cover the area occupied by the outer container in its expanded configuration when viewed from the top or the bottom. The distance the opening of the pocket of insulating material extends from the top flap fold line of the container is also generally equal to or greater than one half the width of the narrowest side wall. As a result, the top of the pocket has sufficient material to cover the area occupied by the bottom of the outer container, when viewed from the top or the bottom, in its expanded configuration. The top of the pocket also generally has sufficient material to allow sealing of the top of the pocket, even in its expanded configuration, when the opening of the pocket of insulating material extends from the top of the container a distance greater than one half the width of the narrowest side wall.

A means for attaching the pouch to the blank, or to the interior of the tubular section of the outer container, is generally utilized in the present invention, generally in the form of an adhesive. The attachment means, when used, is located on both sides of the pouch in one preferred embodiment, along lines at a distance from the edges of the pouch of just over one-half the width of the folding sidewalls of the container. When the pouch is properly placed on the blank during construction, the adhesive may be applied to the pouch along such lines on the pouch, or along the areas of the non-folding side panels near their edges (i.e., near the “corners” of the outer container once the side panels are folded and the container expanded), or along each of these areas. These are the primary areas for attachment between the pocket and the outer container. In one embodiment of the present the invention the pocket must be attached in this fashion, at or near both side edges, to all four corners of the outer container (when expanded), near the fold lines at the intersection of the sidewalls. The attachment between the pocket and sidewalls is accomplished preferably by adhesive placed between the material of the pocket and the area adjacent the edges of the wider sidewalls, however the means for attachment of the insulating material to the corners of the outer container may be glue, tape, a combination of glue and separable tape of the “velcro” type, or by any other means which does not pierce the pouch material, or cause unequal strain at any point in the material. Methods of attachment which allow for removal of the insulated pocket from the outer container have the additional advantage of allowing cleaning of the pocket after separation from the cardboard, thereby preserving the structural integrity of the cardboard against weakening by contact with water, and recycling the outer container and insulative pocket separately.

It should be specifically noted here that, while the adhesive or other attachment means set forth above assists in maintaining the pouch in its proper position within the outer container, and assists expansion of the pouch when the outer container is expanded, attachment means is not necessary to all embodiments of the present invention. In some embodiments the pouch may simply reside within the tubular section of the outer container during shipment, and the pouch will expand within the outer container during use, both by action of the sidewalls against the pouch, and by action of the contents of the pouch as such contents require volume within the pouch when placed within it.

Once the tubular assembly with folded bottom and attached pouch are constructed according to the apparatus set forth herein, a user wishing to employ the present invention may, as noted more fully below in relation to the method of the present invention, simply grasp the tubular assembly, manipulate it to expand the assembly by moving the non-folding side panels apart, and lock the assembly in its expanded configuration by locking the folding side panel bottom flaps into the non-folding side panel flaps, by taping or gluing the bottom flaps to each other or to the side walls of the now expanded container, or by other appropriate means. In its expanded configuration, the assembly of the present invention is open to accept articles for shipment or carrying, closed at the bottom, capable of closure at the top by means of top flaps and excess material at the top of the pocket, and, once so closed, a container having an exterior hard shell, and a water-tight interior pouch resistant to transfer of heat into or out of the container.

The manufacture of the present invention involves a series of steps, beginning with the cutting of a blank for the tubular assembly from a rigid or semi-rigid material. In such manufacture, a measure of such material sufficient to create the finished product is cut to create a flat blank having the requisite side panels and flaps. The blank may be scored or pressed along appropriate lines during cutting to create the scores or fold lines of the blank of the present invention, or such scoring or pressing may take place before or after such cutting of the blank. A measure of insulative and water-tight material sufficient in size to create a pocket or pouch of appropriate size is also cut, folded, and sealed along at least two sides (leaving open at least one side). The pocket is, once formed, placed at the correct position on the blank, or upon adhesive residing on the blank, or adhesive is applied to the pocket and then the pocket is placed at the correct position upon the blank. The blank is then folded over the pocket and the edges at the ends of the blank affixed to one another by additional adhesive or other suitable means. Finally, the distal edge of at least one flap of the non-folding side panels is folded over the edge of the opposing non-folding side panel, or over the distal edge of the opposing flap of the opposing non-folding side panel, and fastened in such position to create a folded bottom for the container. In the alternative, adhesive may be applied to the correct positions on the pocket, or the interior of the tubular section once formed, and the pocket then placed in the correct position within the tubular section, and the tubular section then collapsed to its knock-down configuration. While these methods of construction are stated somewhat generally to provide guidance on the overall process, the preferred method proceeds more specifically as follows:

Starting with a measure of rigid or semi-rigid material, a blank is cut in a shape which, in one embodiment of the present invention, has material sufficient to form four side panels for creating the sidewalls of the present container once constructed, at least one bottom flap at one side of the blank for forming a closure at the bottom of the container once constructed, and at least one top flap at the other side of the blank for forming a closure at the tope of the container once constructed. The bottom flaps are formed of unequal length in one preferred embodiment, the longer bottom flap appended to a non-folding side panel residing between two folding side panels. The blank is also cut to form an end tab at one end of the blank in one preferred embodiment, the end tab usable for affixing one end of the blank to the other end of the blank using adhesive or other suitable means, thereby creating the tubular construction of the container. Before the blank is cut, or in the blank itself as or after it is formed, a number of fold lines or score lines are impressed in the material of the blank, which fold lines define the four side panels, the top flap or flaps, the bottom flaps or flaps, and the end tab. These fold or score lines allow the blank to bend easily between the side panels to create the four sidewalls, to create the top and bottom flaps for closure, and to create the end tab for forming the tubular assembly when the end tab is affixed to the area near the edge of the opposing end of the blank. Two additional fold or score lines are impressed the length of each folding side panel, along the mid line of each such panel. An additional fold or score line is, in one embodiment of the present invention, impressed along a line near the distal edge of the longer bottom flap, for easy bending of that bottom flap once the tubular assembly is formed, and the bottom flaps affixed to one another using attachment means as set forth below.

Starting again with a measure of flexible, thermally insulative, waterproof and air tight “pouch material,” in one preferred embodiment a sheet of such material is cut in the proper shape and size to “fit” the blank. More specifically, the sheet is generally cut in a rectangular shape with a width such that, if the sheet is centered on a non-folding side panel of the rigid blank, the sheet will extend beyond the side edges of that side panel (i.e, beyond the fold or score lines between side panels) a distance of about one-half the width of the folding side panels. The sheet of pouch material is also cut with a length such that, if the sheet is centered on a non-folding side panel of the blank, the sheet, if folded in half, will also extend beyond the bottom edge of that side panel (i.e., beyond the fold or score line between that side panel and the bottom flaps) a distance of about one-half the width of the folding side panels, and beyond the top edge of that panel (i.e., beyond the fold or score line between that non-folding side panel and the top flap or flaps) a distance of at least one-half the width of the folding side panels.

Once cut, the measure of pouch material is generally folded in half upon itself, the edges and ends matched, and the material sealed along its two side edges. Such sealing creates a pouch or pocket in lay flat form comprised of two sides of flexible pouch material, a fold line between the sides of the pouch at its bottom, two sealed side edges, the side edges often showing seal or melt lines where the material is sealed to itself along the edges, and one open end at the unsealed edges across from the fold line. While somewhat less convenient and more bulky, the pouch may also be formed from two separate pieces which together have dimensions approximately equal to the single measure noted above. Such separate pieces may be joined along three edges to create the lay flat pouch with one open end required by the present invention.

Whether formed of a single piece in the preferred embodiment or from two separate pieces, the corners of the pocket adjacent the fold line of the pocket, once formed, may be cut to reduce bulk, and then resealed to regain water-tight and thermal properties. The angle and amount of such cut corner cutting may vary, however the preferred angle of cut is about 45 degrees, and the preferred distance of such cut from the corner of the pouch prior to cutting should be a distance of about one-half the width of the folding side panels of the rigid cut blank. While the corners of the pouch may be cut to reduce bulk in some applications, the preferred embodiment is to leave the corners, which may be easily folded into the container or under the flaps at the bottom of the container during expansion. The material of the corners may also be simply kept together by melting it near the line where the corners might be cut in some embodiments, or melting all the material of the corners of the pouch.

Returning to the flat blank cut from rigid or semi-rigid material, a means for attaching the end of the blank or, in the preferred embodiment, end tab (or tabs) of the blank, is secured to the end of the blank or end tab. As a result, the end tab may be affixed by such attachment means to the area near the edge of the opposing end of the blank, to thereby create a tubular shape from the blank. In a similar way, means for attaching the bottom flaps to one another is secured to at least one bottom flap, near its distal edge. As a result, one bottom flap may be affixed by such attachment means to the opposing, non-folding side panel or, in a preferred embodiment, to the opposing bottom flap. Other attachment means may be secured to both non-folding side panels at least along the areas close to the edges of such side panels. While the areas to which attachment means, when used, are secured may be fairly narrow, a wider placement of such attachment means results in a fuller connection between the pocket and the blank, and ultimately a smoother interior compartment within the pocket once the container is opened to its expanded configuration. In addition, the adhesive or other means of attachment of the pouch to the blank, when used, may be such as to allow removal of the pouch from the container for separate disposal or recycling of the pouch and outer container, or the means for attachment in some applications may be durable to keep the pouch securely within the outer container.

Of course, the steps in the process of the present invention may be reversed in that the attachment means secured to the end tab, bottom flaps, and side panels may be secured to the flat blank prior to formation of the pouch as set forth above, or these steps may be taken in any order (as noted below, attachment means may also be applied to the end tab, bottom flaps, and side panels either before placing the pouch onto the rigid blank or afterwards).

After the rigid or semi-rigid blank is properly cut, and attachment means secured to at least one end tab and bottom flap as set forth above, and after the pouch or pocket of the present invention has been formed from the pouch material has been formed by cutting, folding, and sealing as set forth above, the pocket may then be joined with the blank, and attached to it using the attachment means secured to the blank. This is accomplished in one preferred embodiment by placing the pocket on the blank, and on the attachment means on the non-folding side panels of the blank, so that the pocket is approximately centered over such side panel between two folding side panels, such that the sealed side edges of the pocket extend across the fold or score lines between the non-folding side panel and each folding side panel, and further across about one-half the width of each such folding side panel. In such position, the edges of the pocket extend approximately up to the fold or score line running the length of each folding side panel. In its positioning, the pocket is also placed on the blank as set forth above in a position such that the bottom of the pocket, at the pocket fold line, extends from the bottom edge of the non-folding side panel and across most of the length of the longer bottom flap appended to that side wall (i.e., almost to its distal edge). In such position, the bottom edge of the pocket then extends approximately up to the fold or score line near the distal edge of the longer bottom flap, a distance of approximately one-half the width of the folding side panels. In such position, finally, the top edges of the pocket forming its open end also extend beyond the top edge of the non-folding side panel, and across the top flap attached to that panel, a distance of at least one half the width of the folding side panels.

Once in position on the blank, the pocket may be simply pressed into contact with the attachment means residing along the edges of the non-folding side panel of the blank, to thereby attach the pocket to the blank near such edges, or attach the pocket to a larger area of the wider side panel of the blank wherever the attachment means has been applied to the side panel (as set forth above). In the alternative, the pocket may simply reside in the proper position without attachment means, and the process of construction may continue (as set forth below).

After the pocket is positioned correctly on the blank and attached to the blank using the procedure set forth above, a user may then easily fold one-half of one folding side panel, at the fold line of that panel, over a side edge of the pocket and across the body of the pocket, the user thereby folding the end of the blank over the pocket near its edge a distance equal to about one-half the width of the folding side panel. At the other side of the pocket, a user may also easily fold one-half of the other folding side panel, along with the remainder of the blank, at the fold line of the folding side panel, across the other side edge of the pocket and across the body of the pocket. The user thereby folds the other end of the blank over the pocket near its second edge a distance equal to about the width of the wider side panel plus about one-half the width of the narrower side panel. Of course, the order of folding of the folding side panels over the pocket as set forth above may be reversed with the same overall result.

When each end of the blank has been folded as set forth above, the ends of the blank, or the end tab at one end of the blank and the other end of the blank in the preferred embodiment, or end tabs at each end of the blank, may overlap. Since the ends of the blank, or the end tab at the end of the blank, bear attachment means applied previously as set forth above, construction continues when the ends of the blank, or one or more end tabs at the ends of the blank, overlap, by pressing the ends of the blank, or such end tab and other end of the blank, together. This brings one end of the blank into contact with the attachment means residing along the edge of the other end of the blank, or the end tab, into contact with the attachment means residing along the other end of the blank, thereby securely fastening the ends of the blank together to create a (flattened) tubular arrangement of both wide and narrow side panels (with flaps). Since the pocket of the present invention was appropriately placed on the blank, and fastened to it via appropriately placed attachment means prior to folding the blank in at least one preferred embodiment, the tubular arrangement of side panels, once folded as set forth above, has within it the previously positioned pocket. Since the pocket of the present invention was placed on one non-folding side panel of the blank prior to folding the blank, and since attachment means was appropriately placed on the other non-folding side panel of the blank prior to folding the blank in at least one preferred embodiment, both non-folding side panels of the tubular arrangement of side panels, once folded as set forth above, may be securely attached to the pocket by the attachment means. As a result, the tubular arrangement of side panels after folding has within it, and securely attached to it in some preferred embodiments, the previously placed pocket. If attachment means is used, the areas of attachment of the pocket to the side panels correspond to the area on the non-folding side panels to which attachment means was previously applied. It should be noted that the order of steps in applying the attachment means to the appropriate places to secure the pouch to the blank during construction, of attachment means is used, may be reversed. That is, the attachment means may be applied to the end tab, bottom flaps, and side panels either before placing the pouch onto the rigid blank or afterwards, or in any order, and the attachment means may be applied to either such areas on the blank, or on corresponding areas of the pouch, or both prior, to bringing the pouch and blank together.

After the pocket is positioned correctly on the blank and attached to the blank (in one embodiment) using the procedure set forth above, and the ends of the blank attached to one another as set forth above, a user may then easily fold the edge of the longer bottom flap (appended to one of the non-folding side panels), at the fold line at the distal end of that flap, over the edge of the opposing bottom flap. When the longer bottom flap has been folded as set forth above, the distal edges of the flaps of the non-folding side panels may overlap. Since the area near one or both distal edges of such bottom flaps bear attachment means applied as set forth above, construction continues when such bottom flaps overlap by pressing the areas having such attachment means together. This brings one area of one bottom flap into contact with the attachment means residing along the area of the opposing bottom flap, thereby securely fasten the distal ends of the bottom flaps together to create a folded bottom end for the tubular assembly. Of course, the order of folding of the bottom flaps to create the folded bottom end for the tubular assembly may be reversed without changing the end product, i.e. a tubular assembly, with folded bottom end, and attached pocket within.

As an alternative to the above procedure, for constructing the container of the present invention, the pocket of insulating material may be inserted into the outer container once it has been folded to a tubular assembly, with end tab, opposing blank edge, and bottom flaps secured as above. While not as desirable for a number of reasons, such a procedure may be utilized when a slow set adhesive or other means is used to fasten the pouch to the interior of the tubular section, or when the pocket and outer container are to be constructed without attachment means between them. In such procedure, the pouch is again positioned so that opposite edges at the sides of the pouch extend into the folds of the folding sidewalls of the container, with such edges adjacent the fold lines of such sidewalls. Further, the base of the pouch is positioned so that the fold line at its base extends into the folded bottom created by the bottom flaps when the container is in its knock down position. Once the pocket is in position within the sidewalls of the container, the pocket is attached to the sidewalls near the edges of the corresponding non-folding sidewalls of the outer container as before in those embodiments utilizing attachment means between pouch and outer container.

As a result of manufacture in the method described herein, the present invention, as noted above, may be incorporated into an insulated container assembly which is capable of being folded flat, with side walls of the outside container in the knock down configuration, and with the flattened flexible, sealable, insulative material of the pocket residing within the side walls. To utilize the present invention, a user may select a flattened container of appropriate size, and manipulate the outer container to expand it in the manner set forth herein. Upon such expansion, the flexible, sealable, insulating pocket of one version of the present invention is pulled along with the (non-folding) side walls of the outer container, thereby filling the volume created upon its expansion. At the top of the box, the opening of the pocket opens naturally when the outer container is expanded, thereby allowing placement of articles within the pocket and the outer container. At the bottom of the outer container, the bottom of the pocket is reformed as the corners of the outer container, at the fold lines between side walls, pull the opposing sides of the pocket away from each other. At the same time, and in response to such pulling, the sealed edges of the pocket are pulled inward, in one preferred embodiment, toward the main body of the pocket.

The user continues to expand the outer container until it reaches a point at which the sidewalls are perpendicularly oriented to their adjoining sidewalls, and the bottom or bottom flaps may be manipulated into position to close the outer container at its bottom. At the point of maximum expansion of the outer container, the insulated pocket is reformed so that the pouch material runs substantially all around the inside of the sidewalls, and extends from the top of the container. Meanwhile, as the outer container is opened, the sealed side edges of the pouch near the midline of the folding sidewalls of the outside container are drawn toward the center of the container, as is the fold line of the pouch at the bottom of the container.

At full expansion of the outer container, the bottom of the outer container formed by the joined flaps of the non-folding sidewalls forms a substantially flat surface. The remaining flaps (i.e., the flaps of the folding sidewalls) may then be easily folded over the bottom of the outer container, and secured in place by appropriate means. Such folding over the bottom of the container will also generally result in folding the flaps of the folding sidewalls over the exposed bottom corners of the inner pouch, which normally project from the interior of the contain out between the folding sidewalls and the now straightened flaps of the non-folding sidewalls. In a rectangular “J lock” bottom box design, the bottom closure is normally accomplished when the flaps of the folding sidewalls are folded around the bottom of the container after expansion, and folded into and locked into place in slots formed in the flaps of the non-folding sidewalls. Closure of the pocket at its top then may proceed by folding the pocket material, and securing it in place, or otherwise securing the ends of the pocket material to form a closure. Such closure may be accomplished in a variety of ways currently in use, including use of a “lip & tape” (or lip with adhesive, or pressure sensitive tape) design, with or without folding the edges of the opening to achieve tighter closure. In most cases the pouch material, secured near the edges of the pocket opening, are used to close the pocket upon folding. However, a preferred method of closure in the commercial shipping market is through use of a continuous rotary sealer or heat sealer in which a user may apply, generally by hand, both pressure and heat to melt the edges of the pocket opening together. By such means, a user may create a pocket having water-tight characteristics even if the container as a whole is upended during shipment. Upon completing the closure of the pocket, the user may close the outer container in the way dictated by the design of the outer container.

By the above process, the user may store the insulated and water-tight container assembly in its knock down configuration pending use, select and quickly manipulate assembly to reconfigure the assembly to its final expanded shape, and secure the assembly in such final shape, ready to receive articles. The reconfiguration process is both quick and convenient for the user, and the resultant container inexpensive and readily available. Further, by means of the present invention, a manufacturer may quickly and inexpensively provide a light weight, durable, insulated, and water-tight container which may be manipulated into its final shape by the user, and store and ship such assembly using a minimum of space and cost.

The more important features of the invention have thus been outlined, rather broadly, so that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. Additional features of specific embodiments of the invention will be described below. However, before explaining preferred embodiments of the invention in detail, it may be noted briefly that the present invention substantially departs from pre-existing designs of the prior art, and in so doing provides the manufacturer and distributor with the highly desirable ability to easily and inexpensively manufacture the new assembly in a compact, folded “knock down” configuration, and store or ship the assembly in such configuration while occupying a minimum of space. The design of the present invention has distinct advantages over prior art. Thus, the assembly of the present invention provides an assembly easy for a user to quickly reconfigure into a insulated and water-tight container, which container is suitable for storing or shipping products such as flowers, fruits, beverages, or other products requiring a controlled temperature. It also allows the insulated container incorporating the design to hold fluids and vapor within the container thereby increasing insulative properties of the container, while preventing fluids from leaking through the container with resultant mess and loss of structural integrity. It also provides a water-tight or water-resistant liner in a collapsible, structurally rigid exterior, for space saving storage of thermally sensitive contents and any associated fluids. Accordingly, this water-tight container design satisfies airline cargo regulations relating to shipping with water and ice, and melted ice runoff containment. The rigid exterior of the present invention may itself be manufactured with water resistant adhesives for durability and reusability. Finally, the assembly of the present invention is designed and composed of such materials that it utilizes less material overall in construction and, eventually, disposal, without the use of chlorofluorohydrocarbons (CFCs), while the construction of the assembly allows reuse. Accordingly, the assembly is less environmentally burdensome.

These consequences arising by use of the present invention result in substantial savings in user time, and substantial savings in expense in manufacture and distribution, and reduction in storage area until the user determines that a container having the characteristics noted herein are required, at which point the insulated container system of the present invention is simply applied to the task at hand.

OBJECTS OF THE INVENTION

The principal object of the present invention is to provide a new insulated container assembly for use in transporting temperature sensitive goods, with the additional characteristic of providing a means for retaining fluids and vapors within the container.

A further object of the present invention is to provide an insulated container assembly which may be inexpensively and easily manufactured utilizing standard, readily available materials.

A further object of the present invention is to provide an insulated container assembly which may be transported and stored when not in use in a flattened configuration, thereby preserving space and reducing transportation and storage costs.

A further object of the present invention is to provide an insulated container assembly which is quickly and easily expanded by a user from its folded configuration to its configuration when in use.

A further object of the present invention is to eliminate the need for voluminous, rigid, three dimensional insulating liners which must be carried separately, and placed in position within a container after it has been expanded.

A further object of the present invention is to provide consumers with a convenient, more environmentally sound option to the disposable coolers currently constructed of expanded polystyrene foam.

A further object of the present invention is to provide an insulated, water-tight container utilizing an interior pouch of standard size which may be fitted to a rigid outer container of varying dimensions.

BRIEF DESCRIPTION OF DRAWINGS

The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:

FIG. 1 is a top-side perspective view of a flexible plastic layer having at least one layer of air bubbles entrapped therein laminated to a layer of metalized polyester or foil.

FIG. 2 is a top-side perspective view of the flexible plastic layer of FIG. 1, in which the layer has been folded once, and the edges matched and sealed after folding to create a pouch. In FIG. 2 the corners of the pouch near the fold line have been cut and resealed to reduce bulk.

FIG. 3 is a plan view of a rigid or semi-rigid outer container cut blank prior to assembly, and showing preferred areas for application of adhesive or other attachment means, apparent fold lines, and insertion points for joining bottom flaps after expansion.

FIG. 4 is a top-side perspective view of the rigid outer container of FIG. 3, upon which the pouch or pocket of the present invention has been place, and affixed in its preferred position by contact of the pouch with the attachment means appearing in the preferred areas of FIG. 3.

FIG. 5 is a top-side perspective view of the rigid outer container of FIG. 4, in which the side panels of the blank have been folded toward each other over the pouch, and the end tab at one end of the blank, with its attachment means, placed in contact with the other end of the blank and affixed thereto using the attachment means, thereby creating the tubular arrangement of sidewalls. Prior to completion of construction, FIG. 5 shows the bottom flaps appended to the wider sidewalls in unequal width, prior to folding of one bottom flap over the other to create the bottom, and FIG. 5 also shows each narrower sidewall in folded configuration prior to expansion of the container.

FIG. 6 shows the same top-side perspective view of FIG. 5, still in knock down configuration, but with one bottom flap of one of the wider sidewalls now affixed to the other bottom flap of the other wider sidewall along the area near their distal edges, thereby creating a bottom for the container.

FIG. 7 is a perspective view of the bottom of the rigid outer container of FIGS. 5 and 6, in which the outer container and the flexible plastic pouch of the preceding figures have been expanded to create a volume into which objects may be placed. When so viewed from the bottom, the bottom flaps, which have been affixed to each other near their distal edges, have unfolded to create a bottom for the container while the container expands. At the same time the pouch affixed to the interior of the container sidewalls has also expanded.

FIG. 8 is a top-side perspective view of a the rigid outer container of FIG. 7, wherein the flexible plastic pouch has followed the side walls of the outer container in its expansion, thereby opening the interior of the pouch to receive objects, with the free top edges of the pouch extending beyond the body of the container to allow closure of the pouch with the material so extending.

FIG. 9 is a flow chart diagram of the process of manufacturing the present invention from rigid or semi-rigid material (to form the blank), and flexible, waterproof, air-tight, and insulated material (to form the pouch or pocket).

DESCRIPTION OF A FIRST PREFERRED EMBODIMENT

Referring initially to FIG. 1, a flexible plastic layer 5 having at least one layer of air bubbles entrapped therein laminated to a layer of metalized polyester or foil (sometimes commonly known as “bubble wrap”) is shown. The layer 5 has edges 11 at each end, edges 12 along each side of the layer.

In FIG. 2, the flexible plastic layer 5 of FIG. 1 is shown folded midway along fold line 13, end edges 11 have been matched with each other, and side edges 12 have been matched with themselves. In such position, side edges 12 are sealed along their length, generally creating a seal line 14. Upon sealing, the layer 5 forms a pouch or pocket 10 with an opening 15, two sealed side edges 12, and a fold of continuous material at the central fold line 13. In FIG. 2, the pouch of flexible plastic is may also be cut at its corners 16 near the central fold line 13 to reduce bulk of the pouch 10 once it is positioned within the rigid container sidewalls of the container after expansion. However, in most cases such cuts at corners 16 is not necessary, the excess material being easily folded later between bottom flaps of the container. The angle of cut for the corners 16 appearing in FIG. 2, if such cuts are made, is the preferred angle of about 45 degrees. The amount of material cut from corners 16, if such cuts are made, is the amount removed when cutting at a 45 degree angle at a distance from the corner 16 of the pouch 10 of about one-half the width of the narrower side panels of the outer container. FIG. 2 two shows the cut edges 17 where the corners 16 of pouch 10 have been removed, and corner seal lines 18 as cut edges 17 have been resealed to retain the water-tight and thermal properties of the pouch 10 prior to cutting corners 16. However, as noted above, the pouch corners may remain uncut in many applications with good effect.

Referring now to FIG. 3, a single piece of rigid or semi-rigid outer container material is shown cut into a blank 20 laying flat prior to its assembly. Top flaps 21, bottom flaps 22, non-folding side panels 23, folding side panels 24, and a single end tab 25 are formed from the rigid container material by cutting away excess material. At the end of blank 20 opposite end tab 25, blank mating edge 31 is shown.

After cutting the container blank, or at the same time as the blank is cut, fold lines 9 are pressed into blank 20 between non-folding side panels 23 and folding side panels 24, to provide a means for easy folding of all side panels against one another. As a result of pressing such fold or score lines into blank 20, top flaps 21 and bottom flaps 22 may be easily folded at top flap fold lines 28 and bottom flap fold lines 29, and all side panels may be easily folded against one another. Additionally, fold or score lines 30 are pressed or scored into folding side panels 24 of blank 20 midway between non-folding side panels 23, to allow easy folding of narrow side panels in half lengthwise (i.e., top to bottom in the expanded container). Additionally, end tab fold line 6 is pressed or scored at the end of blank 20 to allow easy bending of end tab against the body of blank 20. Finally, bottom flap fold line 7 is pressed or scored into bottom flap 22 to allow easy bending along the edge of bottom flap 22, thereby allowing flap area 19 of bottom flap 22 to bend for attachment to opposing bottom flap 22, and so allow flexure of bottom flaps one against the other after such attachment so that the container of the present invention may be collapsed or expanded as needed. Fold line 7 in this preferred embodiment is formed as two fold lines pressed into the blank close together, allowing the volume within this fold in the knockdown configuration to vary, thereby allowing the container to easily fit around pouch material of different thickness.

FIG. 3 also shows first preferred areas 26 as preferred areas for application of fastening means, generally adhesive, which will eventually be used to attach the pouch of FIG. 2 to the container blank 20. Preferred areas 26 are the most important areas to establish such attachment, as these preferred areas correspond approximately to a distance from the edges 12 of the pouch 10 of about one-half the width of the folding side panels 24 of the blank 20. In such position, attachment between non-folding side panels 23 and the pouch will allow non-folding side panels 23 to open the pouch 10 upon expansion of the container prior to use. However, additional adhesive may be applied to other, secondary attachment areas 27, or even over the area of the entire area of the non-folding side panels 23 in some applications if additional strength is desired. Adhesive is also applied to attachment area 19 for attaching bottom flap 22 to opposing bottom flap 22.

When constructed as set forth in FIG. 3, a convenient method of manufacture of the outer blank 20 is disclosed, so as to make assembly with pouch 10 possible with minimal expense and effort. In such assembly, outer blank 20 is first cut as shown in FIG. 3, and adhesive (not shown), or an adhesive strip (not shown), is applied or secured to the preferred areas 26, after which pouch 10 is set on blank 20 so that the pouch rests between folding side panel fold lines 30. In such position a mid-line of pouch 10, running from the mid point of opening 15 to the mid point of fold line 13, is equidistant from such fold lines 30. Pouch 10 is also positioned so that pouch fold line 13 rests at or near bottom flap fold line 7. In such position the top edges 11 of pouch 10 rest near the distal edge of top flap 21. By such placement, pouch 10 is placed in contact with the adhesive or adhesive strip of the preferred areas 26 near the edges of wider panels 23, and is thereby secured to such areas 26. In such position, pouch end edges 11 may extend beyond top flaps 21, however pouch bottom at fold line 13 should not extend beyond bottom fold line 7 of bottom flap 22.

After placement of pouch 10 as described above, the ends of blank 20 may be folded across pouch 10 in such a way as to position end tab 25 over the outside of mating edge 31, and fastening flap 25 may then be secured to mating edge 31 utilizing the same adhesive used to secure pouch 10 to preferred areas 26 of blank 20. After placement of pouch 10 as described above and folding of ends of blank 20 as described above, the distal edge of flap 22 and the fastening area 19 proximal to that edge, may be folded across the bottom edge 13 of pouch 10 in such a way as to position fastening area 19 over the outside of the mating edge 8 of opposing bottom flap 22 and fastening area 19 may then be secured to mating edge 8 utilizing the same adhesive used to secure pouch 10 to preferred areas 26 of blank 20. In this way, a single application of adhesive may be used to secure the pouch 10 to blank 20 at preferred areas 26, to close blank 20 over pouch 10 during assembly to create a tubular form, and to seal opposing bottom flaps 22 one to the other along bottom flap attachment area 19 to create a flexible bottom for the container of the present invention.

In FIG. 4, the rigid or semi-rigid blank 20 is shown in perspective view, with pouch 10 placed in position as set forth above. In FIG. 4, pouch 10 rests between folding side panel fold lines 30, with pouch edges 12 on each side of pouch 10 resting near such fold lines 30. In such position a mid-line of pouch 10, running from the mid point of opening 15 to the mid point of fold line 13, is equidistant from such fold lines 30. Pouch 10 is also positioned so that pouch fold line 13 rests at or near bottom flap fold line 7. In such position the top edges 11 of pouch 10 rest near the distal edge of one of top flaps 21. By such placement, pouch 10 is placed in contact with the adhesive or adhesive strip of the preferred areas 26 under pouch 10 (not shown) near the edges of wider panels 23 under pouch 10 (not shown) and is thereby secured to such areas 26. In such position, pouch end edges 11 may extend beyond top flaps 21, or not, however pouch bottom at fold line 13 should not extend beyond bottom fold line 7 of bottom flap 22. End tab 25 is shown with its area for adhesive distal to end flap fold line 6, and preferred areas for adhesive 26 on non-folding side panels 23, however in FIG. 4 blank 20 has not yet been folded along fold lines 30, but rather remains in open position.

In FIG. 5, the rigid or semi-rigid blank 20 is shown in the same perspective view of FIG. 4, with pouch 10 placed in position as before. However, in FIG. 4, blank 20 has been folded along narrower panel 24 fold lines 30, and the ends of blank 20 have been fastened together utilizing end tab 25 affixed over and to the area adjacent blank mating edge 31 (not shown) of non-folding side panel 23. By such affixation, an angular tube of rigid or semi-rigid material capable of lying flat (as shown) is created, which tube may also be expanded into a rectangular tube shape (as shown in FIG. 7). Such expansion is accomplished by a user when a container is needed, by bending at fold lines 9 between non-folding side panels 23 and folding side panels 24. In FIG. 5, the tubular construction of the now folded blank 20 surrounds pouch 10, with pouch bottom fold 13 appearing between bottom flaps 22, and extending approximately up to bottom flap fold line 7. Top flaps 21 are attached to the main body of the blank at fold lines 28, while bottom flaps 22 are attached to the main body of the outer container at fold lines 29. The blank has been folded at fold lines 30, while additional fold lines 9 (top fold line only is shown) allow expansion of the blank 20 into the tubular configuration.

In FIG. 6, the blank 20 is again shown, and again folded along fold lines 30, with additional fold lines 9, and end tab 25 secured to non-folding side panel 23 near blank mating edge 31 (not shown) as in FIG. 5. In FIG. 6, however, bottom flap 22 underneath pouch 10 has been folded at bottom flap fold line 7 over the bottom fold 13 of pouch 10, and secured to opposing bottom flap 22 on the upper side of the container. By such folding and securing, a flexible bottom for the container is created which allows expansion and contraction of the container as desired.

In FIG. 7, the rigid blank 20 is again shown viewed from its bottom, but in its expanded configuration, with bottom flaps 22 and bottom flap fold lines 29 nearest the viewer, and top flaps 21 and top flap fold lines 28 away from the viewer. One fold line 30 is again apparent, however fold lines 9 are, in the expanded configuration apparent as the lines of intersection between non-folding side panels 23 and folding side panels 24. Pouch end edges 11 may are apparent extending beyond top flaps 21. However, pouch 10 is no longer apparent through the bottom of the container, as interior bottom flaps 22 have been manipulated from their fold down configuration to their expanded configuration. As interior bottom flaps 22 have been fastened together along bottom flap attachment area 19 to create a flexible bottom, the bottom of the container is now closed, with pouch 10 on the interior, and exterior bottom flaps 22 remaining to be folded into position and locked in place. In such position, and because of the previous attachment of pouch 10 to blank 20 along attachment areas 26 (now shown), the pouch has followed the sidewalls 23 and 24 of the blank 20 in its expansion, thereby also expanding pouch 10. The cut corners of pouch 10 have largely withdrawn into the container in FIG. 7, thereby saving volume within the container and bulk when folding the remaining bottom flaps 22 into position over the bottom of the container formed by the interior bottom flaps 22. However, as noted above, pouch 10 may also be formed without cutting corners 16, in which case the material forming such corners may be simply folded across the bottom formed by interior bottom flaps 22. Such folding over the bottom of the container will also generally result in folding the flaps of the folding sidewalls over the exposed bottom corners of the inner pouch, which normally project from the interior of the contain out between the folding sidewalls and the now straightened flaps of the non-folding sidewalls. A user may continue expansion by folding exterior bottom flaps 22 over the bottom of the container, and locking the exterior bottom flaps 22 into slots formed in interior bottom flaps 22, or by sealing the exterior bottom flaps in position or together with tape or by other conventional means, a solidly constructed bottom for the container is formed which holds the container open, and ready to receive articles for transport or storage.

Referring to FIG. 8, the rigid container of the present invention is again shown in perspective, from the top, the blank 20 again fully folded at fold lines 9 and expanded to straighten fold line 30 of folding side panels 24. Pouch 10 again appears in expanded configuration as it has expanded with the expansion of the container wider sidewalls 23, and top flaps 21 and pouch opening 15 appear open for receiving objects. In its expanded configuration, the blank 20 has been opened up by bending at its fold lines 7, and straightening sidewalls 24 at fold lines 30. The pouch 10 appearing in FIG. 2 has followed the side walls of the outer container 20 in FIG. 7, both at the top and the bottom of the pouch 10. Accordingly, pouch top edges 11 are pulled open by the adhesive at the interior corners of the outer container applied at the preferred areas 26, shown in FIG. 3, creating opening 15 in the pouch 10 through which objects may be passed for placement within the pouch 10.

Referring now to FIG. 9, the process of manufacturing the present invention is shown in flow chart form. In FIG. 9, rigid or semi-rigid material is selected to form a blank 100 of suitable characteristics, and a blank is prepared. In such material, fold lines or score lines are pressed or scored 101, and a blank of the desired size and shape is then cut 102 as set forth above to produce a blank with fold lines or score lines in the correct positions. The blank may be cut 103 and then pressed or scored 104 as set forth above to produce fold lines or score lines at the correct positions in the material of the blank. However, the most usual method with operations of this kind, and the preferred method within the scope of the present invention, is to accomplish the cutting of the blank 102/103 simultaneously with the scoring or pressing of the blank 101/104, “cookie cutter” fashion, utilizing a single cutting and stamping die in a single step. Whether the blank is cut before, after, or with the placement of fold lines or score lines, attachment means, generally an adhesive, may then be applied 105 to preferred attachment means areas 26, or additionally to preferred attachment means 27, or additionally to one entire surface of each of the non-folding side panels 23.

Before or after the above series of steps taken to prepare a blank, or before or after any such steps, a flexible, waterproof, air-tight, and insulated material is selected to form a pouch 120 of suitable characteristics, and a pouch is prepared. From such material, a rectangle may be cut 121, and the rectangle folded 122. In the alternative, two squares or rectangles may be cut 123 having the same area as the folded rectangle to produce a pouch having the same volume. Whether a single rectangle is cut 121 and folded 122 or two rectangles are cut 123, the loose edges of the material so cut are matched 124, at least approximately, for later sealing, or cutting and sealing. Once the edges of the material are matched 124, the manufacturer may elect to simply seal the side edges 125 (or side and bottom edges in the case of a pouch formed from two pieces of material), thereby creating a pouch 10 with opening 15, and corners 16. In the alternative, the manufacturer may elect to cut the corners 126 of the pouch 10 after sealing, and seal the cut edges where the corners were cut away 127, thereby creating the same pouch but with shortened (or not) corners. The manufacturer may in the alternative cut the edges and corners 128 of the material simultaneously 128 after matching edges 124, and seal the side edges and cut edges where the corners were cut away 129 if a pouch without corners is desired.

Once a blank is prepared and a pouch is prepared using the above method, the pouch is placed on the blank 150 in the correct position as set forth above, between fold lines 30, and the pouch is pressed into the attachment means 151 of areas 26 (or so much attachment means as is present in areas 26, 27, and the remainder of non-folding side panel 23). Once the pouch is securely affixed to the blank, the blank may then be folded 152 at side panel fold lines 30, so that end tab and matching edge of the blank overlap, and end tab and the area at the end of the blank, near its matching edge may be fastened together 153, thereby creating an angular tubular arrangement of sidewalls. Once the tubular arrangement of sidewalls has been created, that longest bottom flap having an area for fastening 19, may then be folded 154 over the pouch 10, and over the edge of opposing bottom flap 22, and the attachment means of that area for fastening 19 used to fasten the first bottom flap to the opposing bottom flap 155. 

1. A water-resistant container, comprising: a container having a first folding sidewall and a second folding sidewall, the first and second folding sidewalls being opposing container sidewalls, the first and second folding sidewalls each having two opposing edges creating widths, the first and second folding sidewalls having fold lines approximately midway between their opposing edges, the fold lines running approximately from the top of each of the first and second folding sidewalls to the bottom of each of the first and second folding walls, the container having a first non-folding sidewall and a second non-folding sidewall, the first and second non-folding sidewalls being opposing container walls, the first and second folding sidewalls affixed at two of their edges to two edges of the first and second non-folding sidewalls to form a tubular section, the tubular section having a top end and a bottom end, the first end of the tubular section having a plurality of flaps attached thereto, the second end of the tubular section having a plurality of flaps attached thereto, the first and second folding sidewalls and the first and second non-folding sidewalls having interior surfaces facing the interior of the tubular section and exterior surfaces facing the exterior of the tubular section, the intersection of the edges of the first and second folding sidewalls with the edges of the first and second non-folding sidewalls creating corners of the container, the first and second non-folding sidewalls having areas near the corners of the container, on the interior surfaces of the non-folding sidewalls, for attachment means, and a pouch having an interior, a first exterior side, a second exterior side, a bottom edge, a right edge, a left edge, a plurality of top edges forming a top opening, the pouch being formed from a flexible and water-resistant material, the pouch residing within the tubular section of the container, the right edge of the pouch residing near the fold line of the first folding sidewall and the left edge of the pouch residing near the fold line of the second folding sidewall, the top edges of the pouch extending from the top end of the tubular section at least a distance equal to one-half the width of the folding sidewalls, the bottom edge of the pouch extending from the bottom end of the tubular section at least a distance equal to one-half the width of the folding sidewalls.
 2. The water-resistant container of claim 1, further comprising means for attaching the first exterior side of the pouch to the attachment areas of the first non-folding sidewall, and means for attaching the second exterior side of the pouch to the attachment areas of the second non-folding sidewall.
 3. The water-resistant container of claim 2, wherein the flexible and water-resistant material is also thermally insulative.
 4. The water-resistant container of claim 3, wherein the flexible, water-resistant, and thermally insulative material comprises at least one layer of material having bubbles of gas entrapped therein.
 5. The water-resistant container of claim 4, wherein the flexible, water-resistant, and thermally insulative material further comprises at least one layer of reflective material.
 6. The water-resistant container of claim 5, wherein the means for attaching the pouch to the interior surfaces of the walls of the outer container comprises an adhesive.
 7. The water-resistant container of claim 6, wherein the means for attaching the pouch to the interior surfaces of the walls of the outer container comprises a releasable adhesive.
 8. The water-resistant container of claim 7, further comprising means for sealing the pouch top opening.
 9. The water-resistant container of claim 1, wherein the flexible and water-resistant material is also thermally insulative.
 10. The water-resistant container of claim 9, wherein the flexible, water-resistant, and thermally insulative material comprises at least one layer of material having bubbles of gas entrapped therein.
 11. The water-resistant container of claim 10, wherein the flexible, water-resistant, and thermally insulative material further comprises at least one layer of reflective material.
 12. A thermally insulative container, comprising: a container having a first folding sidewall and a second folding sidewall, the first and second folding sidewalls being opposing container sidewalls, the first and second folding sidewalls each having two opposing edges creating widths, the first and second folding sidewalls having fold lines approximately midway between their opposing edges, the fold lines running approximately from the top of each of the first and second folding sidewalls to the bottom of each of the first and second folding walls, the container having a first non-folding sidewall and a second non-folding sidewall, the first and second non-folding sidewalls being opposing container walls, the first and second folding sidewalls affixed at two of their edges to two edges of the first and second non-folding sidewalls to form a tubular section, the tubular section having a top end and a bottom end, the first end of the tubular section having a plurality of flaps attached thereto, the second end of the tubular section having a plurality of flaps attached thereto, the first and second folding sidewalls and the first and second non-folding sidewalls having interior surfaces facing the interior of the tubular section and exterior surfaces facing the exterior of the tubular section, the intersection of the edges of the first and second folding sidewalls with the edges of the first and second non-folding sidewalls creating corners of the container, the first and second non-folding sidewalls having areas near the corners of the container, on the interior surfaces of the non-folding sidewalls, for attachment means, and a pouch having an interior, a first exterior side, a second exterior side, a bottom edge, a right edge, a left edge, a plurality of top edges forming a top opening, the pouch being formed from a flexible and thermally insulative material, the pouch residing within the tubular section of the container, the right edge of the pouch residing near the fold line of the first folding sidewall and the left edge of the pouch residing near the fold line of the second folding sidewall, the top edges of the pouch extending from the top end of the tubular section at least a distance equal to one-half the width of the folding sidewalls, the bottom edge of the pouch extending from the bottom end of the tubular section at least a distance equal to one-half the width of the folding sidewalls.
 13. The water-resistant container of claim 12, further comprising means for attaching the first exterior side of the pouch to the attachment areas of the first non-folding sidewall, and means for attaching the second exterior side of the pouch to the attachment areas of the second non-folding sidewall.
 14. The thermally insulative container of claim 13, wherein the flexible and water-resistant material is also water tight.
 15. The thermally insulative container of claim 14, wherein the flexible, water-resistant, and thermally insulative material comprises at least one layer of material having bubbles of gas entrapped therein.
 16. The thermally insulative container of claim 15, wherein the flexible, water-resistant, and thermally insulative material further comprises at least one layer of reflective material.
 17. The thermally insulative container of claim 16, wherein the means for attaching the pouch to the interior surfaces of the walls of the outer container comprises an adhesive.
 18. The thermally insulative container of claim 17, wherein the means for attaching the pouch to the interior surfaces of the walls of the outer container comprises a releasable adhesive.
 19. The thermally insulative container of claim 18, further comprising means for sealing the pouch top opening.
 20. The thermally insulative container of claim 12, wherein the flexible and water-resistant material is also thermally insulative. 